Firepower FP-125 Operating Manual
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Firepower FP-125 Operating Manual

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See also: Operation Manual and Installation Manual
FP-125
FP-135
FP-165
operating Manual
MINI MIG
Portable MIG Welder
Revision: AA
Issue Date: March 19, 2009
Operating Features:
120
130
Art # A-09075
Manual No.: 0-5123
160

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Summary of Contents for Firepower FP-125

  • Page 1 FP-125 MINI MIG FP-135 Portable MIG Welder FP-165 Art # A-09075 operating Manual Revision: AA Issue Date: March 19, 2009 Manual No.: 0-5123 Operating Features:...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5123 for: FirePower 125 Mini MIG System MIG Welder Part No. 1444-0324 FirePower 135 Mini MIG System MIG Welder Part No.

  • Page 4: Table Of Contents

    Install Wire into the Welding Gun ..............3-9 SECTION 4:OPERATION ..................4-1 4.01 General Safety Precautions ................4-1 4.02 FirePower Controls ..................4-2 4.03 Gas Metal Arc Welding (GMAW) ..............4-4 4.04 Flux Cored Arc Welding (FCAW) ..............4-4 4.05 Shutdown Procedures ..................
  • Page 5 TABLE OF CONTENTS 4.13 FirePower 125 Welding Setting Selection Guide ........... 4-10 4.14 FirePower 135 Welding Setting Selection Guide ........... 4-11 4.15 FirePower 165 Welding Setting Selection Guide ........... 4-12 4.16 Gas Selection for Gas Metal Arc Welding ............4-13 SECTION 5:SERVICE ..................

  • Page 6: Section 1:Safety Instructions And Warnings

    SAFETY INSTRUCTIONS FIREpOwER Fp-125, 135, 165 SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 7 FIREpOwER Fp-125, 135, 165 SAFETY INSTRUCTIONS WARNING WARNING WELDING can cause fire or explosion. FUMES AND GASES can be hazardous to your health. Sparks and spatter fly off from the welding arc. The flying Welding produces fumes and gases. Breathing these sparks and hot metal, weld spatter, hot workpiece, and fumes and gases can be hazardous to your health.
  • Page 8 SAFETY INSTRUCTIONS FIREpOwER Fp-125, 135, 165 WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. ENGINE FUEL can cause fire or explosion. Chipping and grinding cause flying metal. As welds cool, Engine fuel is highly flammable. they can throw off slag.

  • Page 9: Principal Safety Standards

    FIREpOwER Fp-125, 135, 165 SAFETY INSTRUCTIONS ABOUT PACEMAKERS: WARNING The above procedures are among those also normally STEAM AND PRESSURIZED HOT COOLANT can burn recommended for pacemaker wearers. Consult your face, eyes, and skin. doctor for complete information. The coolant in the radiator can be very hot and under 1.02...

  • Page 10: Symbol Chart

    SAFETY INSTRUCTIONS FIREpOwER Fp-125, 135, 165 1.03 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-...

  • Page 11: Precautions De Securite En Soudage A L'arc

    FIREpOwER Fp-125, 135, 165 SAFETY INSTRUCTIONS 1.04 Precautions De Securite En Soudage A L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 12 SAFETY INSTRUCTIONS FIREpOwER Fp-125, 135, 165 1. Portez une casque de soudeur avec filtre oculaire de nuance ap- 1. Eloignez la tête des fumées pour éviter de les respirer. propriée (consultez la norme ANSI Z49 indiquée ci-après) pour 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée vous protéger le visage et les yeux lorsque vous soudez ou que...
  • Page 13 FIREpOwER Fp-125, 135, 165 SAFETY INSTRUCTIONS AVERTISSEMENT AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE LES BOUTEILLES ENDOMMAGEES PEUVENT EX- EXPLOSION PLOSER L’arc produit des étincellies et des projections. Les parti- Les bouteilles contiennent des gaz protecteurs sous cules volantes, le métal chaud, les projections de soudure haute pression.

  • Page 14: Principales Normes De Securite

    SAFETY INSTRUCTIONS FIREpOwER Fp-125, 135, 165 2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. 3. Si c’est possible, laissez le moteur refroidir avant de faire le plein AVERTISSEMENT de carburant ou d’en vérifier le niveau au début du soudage.

  • Page 15: Graphique De Symbole

    FIREpOwER Fp-125, 135, 165 SAFETY INSTRUCTIONS 1.07 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension...

  • Page 16: Section 2:Introduction

    2.04 General WARNING Gives information regarding possible personal The FirePower FP-125, 135, 165 Machines are single- injury. Warnings will be enclosed in a box phase input welding machines and come equipped with such as this.

  • Page 17: Specifications

    FIREpOwER Fp-125,135,165 INTRODUCTION 2.05 Specifications Description FP-125 FP-135 FP-165 Package System Part Number 1444-0324 1444-0326 1444-0328 Power Source Weight 47.4 lb (21.5 kg) 52.9 lb (24.0kg) 58.1 lb (26.4 kg) Power Source Dimensions HxWxD 12 x 9.75 x 17.5" ( 304.8 x 247.7 x 444.5mm) Number of Phases 1 Ø...

  • Page 18: Volt - Amp Curves

    FP-125 FIREPOWER Vin=115V 60Hz Art # A-09076 35.0 30.0 25.0 20.0 15.0 10.0 OUTPUT CURRENT Figure 2-1: Volt/Amp curves of the FirePower 125 FP-135 FIREPOWER Vin=115V 60Hz Art # A-09077 OUTPUT CURRENT Figure 2-1: Volt/Amp curves of the FirePower 135 Introduction Manual 0-5123...
  • Page 19 FIREpOwER Fp-125,135,165 INTRODUCTION FP-165 FIREPOWER Vin=230V 60Hz Art # A-09078 OUTPUT CURRENT Figure 2-1: Volt/Amp curves of the FirePower 165 Manual 0-5123 Introduction...

  • Page 20: Duty Cycle

    117 amps. This means that it has been designed and built to provide the rated amperage, 117 amps, for 2 minutes out of every 10 minute period. During the other 8 minutes of the 10 minute period, the FirePower FP-135 must idle and be allowed to cool.

  • Page 21: Mig Gun Maintenance

    FIREpOwER Fp-125,135,165 INTRODUCTION 2.08 MIG Gun Maintenance Remove dust and metallic particles from the gun conduit by forcing clean, dry compressed air into the conduit once a week. This will minimize wire feeding problems. 2.09 Handle / Feet Assembly Art # A-09094...

  • Page 22: Section 3:Installation

    The FirePower FP-125 has a 19% duty cycle (1 minute 54 seconds of every 10 minutes can be used for welding). The FirePower FP-135 has a 20% duty cycle (2 CAUTION minutes of every 10 minutes can be used for welding).

  • Page 23: Requirements For Maximum Output

    In order to obtain the maximum output capability of the CAUTION FirePower FP-125 a branch circuit capable of 40 amperes KEEP FACE WELL AWAY FROM THE CYLINDER VALVE at 115 to 125 Volts 60 Hz is required. In order to obtain DURING “CRACKING”.
  • Page 24 INSTALLATION FIREpOwER Fp-125, 135, 165 Shielding Regulator and Flow Meter “Cracking” Shielding Shielding Shielding Art # A-07965 Gas Hose Figure 3-1 Gas Cylinder Installation for Reference Only! Installation Manual 0-5123...
  • Page 25 FIREpOwER Fp-125, 135, 165 INSTALLATION Adjusting Regulator Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-2 and data charts. Approx. 20 CFH) The gas flow rate should be adequate to cover the weld zone to stop weld porosity.

  • Page 26: Attaching The Gun And Cable Assembly To The Power Source

    FIREpOwER Fp-125, 135, 165 3.07 Attaching the Gun and Cable Assembly to the Power Source The Firepower FP-125, FP-135, FP-165 are supplied with a 80A MIG gun. The 80A MIG gun is designed with an ergonomic handle and fewer parts to eliminate perfor- mance problems.

  • Page 27: Polarity Changeover

    FIREpOwER Fp-125, 135, 165 INSTALLATION 3.08 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions As delivered from the factory, the output polarity is set to the polarity which matches the welding wire supplied with the unit.

  • Page 28: Installing Wire Spool

    INSTALLATION FIREpOwER Fp-125, 135, 165 3.09 Installing Wire Spool 3.10 Feedrolls As delivered from the factory, the unit is set for an 4” A feedroll consists of two different sized grooves, .023” (102mm) spool. (0.6mm) and .030” / .035” (0.8mm / 0.9mm).
  • Page 29 FIREpOwER Fp-125, 135, 165 INSTALLATION Pressure Arm Pressure Adjust Device CAUTION Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly and do not let go of it. Make sure that the end of the wire is free of any burrs and is straight.

  • Page 30: Install Wire Into The Welding Gun

    3.12 Install Wire into the Welding Gun 3. Set the wire feed speed to half-way or "5". 1. Plug the Welding Power Source into the 120VAC Wire Feed receptacle for the FirePower FP-125 and FP-135, Speed and into the 230VAC receptacle for the FirePower FP-165.
  • Page 31 FIREpOwER Fp-125, 135, 165 INSTALLATION 4. Straighten the gun cable. Remove the nozzle and contact tip from the MIG welding gun (see Section 2.08). WARNING If ground connection clamp is in place on the workpiece the electrode wire is electrically “hot”...

  • Page 32: Section 4:Operation

    OpERATION FIREpOwER Fp-125, 135, 165 SECTION 4: OPERATION 4.01 General Safety Precautions Read and understand the safety instructions at the beginning of this manual prior to operating this machine. WARNING Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding helmet, with proper lenses installed).

  • Page 33: Firepower Controls

    FIREpOwER Fp-125, 135, 165 OpERATION 4.02 FirePower Controls 10 The Gun Switch Connector is provided for con- nection of the Gun Switch Leads. Refer to Figure 4-1 and 4-2. 11. Negative (-) Welding Terminal. 1. Power ON / OFF switch turns the power on and 12.
  • Page 34 Figure 4-1: FirePower FP-125 Controls 120V Wire Feed Welder Welds 24 gauge to 1/4" (6.4mm) Mild Steel RATED OUTPUT VOLTS AMPS DUTY CYCLE MAX OCV AMP RANGE 39-120 39-120 FP-135 Art # A-09066 Figure 4-2: FirePower FP-135 and 165 Controls Operation Manual 0-5123...

  • Page 35: Gas Metal Arc Welding (Gmaw)

    Plug the supply cord into a 120 VAC 40 Ampere recep- Close the cylinder valve (GMAW process only). Press gun tacle for the FP-125, 120 VAC 50 Ampere receptacle for switch to vent gas line (GMAW process only). Place the the 135 and into a 230 VAC 30 Ampere receptacle for the POWER ON/OFF SWITCH in the OFF position.

  • Page 36: Basic Welding Technique

    Setting of the power Supply ated. The process can be used to weld thin and fairly thick The settings of the FirePower requires some practice by steels, and some non-ferrous metals in all positions. the operator in that the welding Power Supply has two control settings that need to balance.

  • Page 37: Welding Gun Positions

    POLARITY – DCEP (Direct Current Electrode Positive) or DCEN (Direct Current Electrode Negative) WIRE FEED SPEED – 1 to 10 VOLTAGE RANGE SWITCH SETTING – 1 to 4 for FP-135, 165 an two switches and1-2 and Low-High for FP-125. GAS FLOW RATE – 15 to 25 CFH (If shielding gas is required) ELECTRODE WIRE STICK-OUT –...

  • Page 38: Mig Welding (Gmaw) Variables

    OpERATION FIREpOwER Fp-125, 135, 165 4.08 MIG Welding (GMAW) Variables 2. Wire Feed Speed. Increase in wire feed speed in- creases weld current. Decrease in wire feed speed Most of the welding done by all processes is on carbon decreases weld current.

  • Page 39: Establishing The Arc And Making Weld Beads

    FIREpOwER Fp-125, 135, 165 OpERATION 4.09 Establishing the Arc and Making 4.11 Welding Procedure Weld Beads 1. Maintain the tip to work distance (stickout) at 5/16” to 3/8” (8 to 9mm) at all times. Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample 2.

  • Page 40: Reference Tables

    OpERATION FIREpOwER Fp-125, 135, 165 4.12 Reference Tables The following tables are provided as user aids when performing MIG or FLUX CORED welding. Type of Gas Typical Mixtures Primary Uses Carbon Dioxide (CO2) Mild and low alloy steels Argon (Ar) - Carbon Dioxide (CO2) 75% Ar –...

  • Page 41: Firepower 125 Welding Setting Selection Guide

    FIREpOwER Fp-125, 135, 165 OpERATION 4.13 FirePower 125 Welding Setting Selection Guide Material Type Wire Type Shielding Gas Wire Size and Flow Rate (Diameter) .023" (0.6mm) 100% CO .030" (0.8mm) 25cfh Solid .035" (0.9mm) (or hard) Steel ER70S-6 .023" (0.6mm) 75% Ar .030"...

  • Page 42: Firepower 135 Welding Setting Selection Guide

    OpERATION FIREpOwER Fp-125, 135, 165 4.14 FirePower 135 Welding Setting Selection Guide Material Type Wire Type Shielding Gas Wire Size and Flow Rate (Diameter) .023" (0.6mm) 100% CO .030" (0.8mm) 25cfh Solid .035" (0.9mm) (or hard) Steel .023" (0.6mm) ER70S-6 75% Ar .030"...

  • Page 43: Firepower 165 Welding Setting Selection Guide

    FIREpOwER Fp-125, 135, 165 OpERATION 4.15 FirePower 165 Welding Setting Selection Guide Material Type Wire Type Shielding Gas Wire Size and Flow Rate (Diameter) .023" (0.6mm) 100% CO .030" (0.8mm) 25cfh Solid .035" (0.9mm) (or hard) Steel .023" (0.6mm) ER70S-6 75% Ar .030"...

  • Page 44: Gas Selection For Gas Metal Arc Welding

    OpERATION FIREpOwER Fp-125, 135, 165 4.16 Gas Selection for Gas Metal Arc Welding Base Plate Filler Transfer Suggested Welding Metal Type Thickness Metal Mode Shielding Gas Positions Comments Carbon Greater ER70S-X Short 100% CO All Position High welding speeds. Good penetration and...

  • Page 45: Section 5:Service

    SERVICE FIREpOwER Fp-125, 135, 165 SECTION 5: SERVICE 5.01 Cleaning of the Unit 1. Gas cylinder contents and flow meter. a. Ensure that the gas cylinder is not empty and Periodically remove the right side panel (after disconnect- the flow meter is correctly adjusted to 20CFM ing the supply cord from the receptacle) and blow out the (15 liters per minute).
  • Page 46 FIREpOwER Fp-125, 135, 165 SERVICE 2. Inconsistent wire feed Wire feeding problems can be reduced by checking the following points: 1. Wire spool brake is too tight. a. Feed roller driven by motor in the cabinet will slip. 2. Wire spool brake is too loose.

  • Page 47: Welding Problems

    SERVICE FIREpOwER Fp-125, 135, 165 5.05 Welding Problems FAULT CAUSE REMEDY 1 Undercut. A Welding arc voltage A Reduce voltage by reducing the voltage se- too high. lection switch position or increase the wire feed speed. B Incorrect torch angle B Adjust angle...
  • Page 48 FIREpOwER Fp-125, 135, 165 SERVICE FAULT CAUSE REMEDY 6 Weld cracking A Weld beads too small A Decrease travel speed B Weld penetration nar- B Reduce current and voltage and increase MIG row and deep torch travel speed or select a lower penetration shielding gas.

  • Page 49: Appendix 1: Options And Accessories

    1444-0235 .035" (0.9mm), 2 lbs (0.9kg) Spool 1444-0489 Gas Diffuser E71T-GS Flux Cored Wire, 1444-0236 .035" (0.9mm), 10 lbs (4.5kg) Spool 1444-0741 MIG Gun, Complete Assembly Art # A-09026 Figure A-1: FP-125 Feed Roll and Consumables Chart Appendix Manual 0-5123...
  • Page 50 FIREpOwER Fp-125, 135, 165 AppENDIX Art # A-09028 Art # A-09027 Figure A-2: FP-135 Feed Roll and Consumables Chart Figure A-3: FP-165 Feed Roll and Consumables Chart Manual 0-5123 Appendix...
  • Page 51 AppENDIX FIREpOwER Fp-125, 135, 165 This Page Intentionally Blank Appendix Manual 0-5123...

  • Page 52: Appendix 2: Replacement Parts

    1444-0822 1444-0823 1444-0824 LOWER PANEL, FP-125/135/165 1444-0490 1444-0490 1444-0490 SWITCH 16A, FP-125 1444-0834 THERMOSTAT, XFMER 1444-0470 CONTACTOR *Not shown in art 1444-0498 1444-0498 BACK PANEL FP SILK-SCREEN PRINTED 1444-0818 1444-0819 1444-0820 Table A-1: FP-125 Replacement Parts List Manual 0-5123 Appendix...
  • Page 53 AppENDIX FIREpOwER Fp-125, 135, 165 Figure A-4: FP-125-135-165 Replacement Parts Callout Appendix Manual 0-5123...

  • Page 54: Appendix 3: Firepower 125 System Schematic

    FIREpOwER Fp-125, 135, 165 AppENDIX APPENDIX 3: FIREPOWER 125 SYSTEM SCHEMATIC Art # A-09022 Manual 0-5123 Appendix...

  • Page 55: Appendix 4: Firepower 135 System Schematic

    AppENDIX FIREpOwER Fp-125, 135, 165 APPENDIX 4: FIREPOWER 135 SYSTEM SCHEMATIC Art # A-09023 Appendix Manual 0-5123...

  • Page 56: Appendix 5: Firepower 165 System Schematic

    FIREpOwER Fp-125, 135, 165 AppENDIX APPENDIX 5: FIREPOWER 165 SYSTEM SCHEMATIC Art # A-09024 Manual 0-5123 Appendix...

  • Page 57: Limited Warranty

    LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada. November 2007 LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company (“Thermal Arc”), warrants ® to customers of authorized distributors (“Purchaser”) that its products will be free of defects in workmanship or material.

  • Page 58: Warranty Schedule

    GMAW/FCAW (MIG) WELDING EQUIPMENT ARRANTY ERIOD ABOR Firepower FP-95, FP-125, FP-135, FP-165 Fabricator 140, 180, 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P, 320SP; 400SP; 500SP; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed Original Main Power Transformer and Inductor...

  • Page 59: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 60 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 FAX: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...

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Fp-135Fp-165

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